Metal-casting process and apparatus



Filed July 25, 12329 fb 7 www A INV ENTR PROCESS am; Filed July 25,

3 SheetS-Sheet 2 lNVENTOR M. E. VANS CASTING PROCESS AND APPARATUS METAL 3 sheets-sheet 3 Filed July 25, 1929 INVENTOR 771 M, C Y u @ma n U ,u m D C m Patented Apr.. ld, wm I u raras rarest orari-ca MARTIN E. EVANS, OF KANKAKEE, ILLINOIS METAL-CASTING PROCESS AND .APPARATUS Application led July 25, 1929. Serial No. 380,963.

The invention relates to the art of metal ing remarks and descriptions and accomcasting and particularly to means and methpanying illustrations. ods for casting refractory metals and alloys In the usual art of casting metals, variinto bodies of a Wide range of sizes, shapes, ous difficulties are encountered which cause 5 and mechanical mixtures. Masses of metal defects in the cast product varying with the 55 as large as steel ingots and as small as steel quantity of metal involved in the casting rods are contemplated to be produced by this operation. invention which has for one object the pro- Consideringl the casting of steel as an eX- duction of metal bodies free from piping, ample, and particularly large ingots, piping,

30 blow holes, segregation, large crystals and blowholes, segregation, large crystals and in- 50 internal stresses that usually are associated ternal stresses are physical conditions that with metal casting. are more or less present collectively in spite Another object of the invention is the 'proof various expedients employed to obviate duction of castings of composite metals of them. They are all the result of the phel different melting temperatures. nomena accompanying the cooling of a large 35 Another object of the invention is the promass of metal from the liquid to the solid duction of castings of composite metals so state. To obviate them the present invention that each metal retains the physical propercontemplates the cooling of small particles ties in the casting that it would have if cast of molten metal to the plastic or weldable so 58pm-M8137, state and successivelywelding them together 70 Another object is to produce metal castings in the order of their cooling. of fibrous structure. Because of a premature chilling and solidi- Another object is to produce a metal castying of smaller masses of metal when subing continuously. jected to the cooling action of molds or appa- 25 Another object is to produce a metal castratus contacting with the metal, the producing at a rate uncontrolled by the usual cooltion of strips or small castings of steel have ing rate of the metal cast. been difficult. To obviate this difficulty, the

Another object is to produce castings that present invention provides a heat conveyor solidify from the body center towards the or vehicle and a temperature regulator in the 50 periphery instead of in the reverse order form of a slag of characteristics compatible 30 which is usual. with the character of the metal with which it Another object is to provide a washing and cooperates. The same heat conveyor and tempurification of the metal as it is being cast. perature regulator is employed in the produc- Another object is to reduce the nonmetallic tion of the larger mass of metal, which is com- 35 inclusions of metals cast. parable to the usual standard ingot, as is used Another obj ect is the placement of metallic for the production or" strips or small castings. particles in denite relative positions in a When two pieces of steel are to be welded casting. together it is customary to coat them with a Another object is `to provide a means for flux or Welding cinder, then to heat them to '19 maintaining a Welding heat in the portions of a Welding temperature and to hammer them 99 a casting already cast pending the placement together at the point of welding temperature thereon of successive portions, that are plasthereby forcing the Welding cinder aside and tic and at a Welding heat. eiecting a chemical union of the metal. A

Another object of the invention is the proportion of the Welding cinder is inevitably 45 duction. of a casting with a homogeneous entrapped between the two pieces but not in mixture of metals of Widely varying specific quantity suiicient to be detrimental. Congravity and melting points. tinued l'iammeringv during the cooling of the To these ends special processes and means Weld prevents crystal growth and preserves for carrying them out are provided which the quality of the metal. The welding cinder 5@ will be readily understood from the followservesthe very useful purpose of protecting the metal from oxidation during the operation. The present invention contemplates the constant repetition of these operations with particles of metal as the are changed from the molten to the plastic or Weldin state. Pressure between the weldable partlcles is quickly applied after the particles attain the weldable state, particle adhering to particle as a result thereof and the excess welding cinder or slag being expressed iecemeal therefrom. The gradual accumu ation of particles results in the building up of a solid metal body including a minimum of the iluxin or welding cinder by reason of the partie e by particle welding and express- A it is subjected to pressure to remove the slag content or reduce it. This means that particles of welded metal must be forced apart to provide a. path of exit for the slagthe path being subsequently welded shut. normous pressures necessitating expensive apparatus are required for these o erations an in proportion to the masses o material involved in the ueezing and welding operations. Hand pudd ing operations involve masses ot ft to two hundred pounds of metal. Mechanical puddling operations or mechanical production ci wrought iron involve masses up to two thousand pounds of metal. lt is at once a dparent that these masses must include consx erable slag inclusions and representative samples show 2% to 5% inclusions after squeezing.

ln the practice of the present invention, in some cases squeezing and pressure are exerted as the particles of metal are cha from the molten to the crystal or plastic state and not as a se arate and subsequent o eration as in the fore-mentioned methods of wrought iron production, the product having e, variable slag contentdown to less than one and one-half per cent. The slag serves as a vehicle in which the metal is conveyed while changing from a molten or fluid condition into a plastic or crystal state and delivered in close proximity to a body of worked metal in a condition for receiving further additions by welding. The continued arrival of slag articles with the metal' particles conve s heat to and regulates the temperature o e growing or accumulating body of metal, since heat is continuously being abstracted from the accumulating body of metal b conduction and radiation. Theenergvof emoving remesa particles of both slag and metal is utilized to eect the initial union between metal particles, makingwelding operations successful at somewhat lower temperatures than are employed in puddling and mechanical wrought iron production and at the same time ex ressing portions of slag from between meta particles and edectin a welding action in the vicinity ofthe disp aced slag. However, simple How of cast metal and contact of successive particles also is contemplated to build the body of cast metal and its associated material.

This invention makes available for the first time mechanical mixtures of metals which if 'mixed together in the molten state for casting dilute and intermiX to form a vuniform analysis. rlhus, a high carbon steel and a low carbon steel when brought together in molten states in equal uantities blend together to produce a medlum carbon steel o uniform analysis. However, by the present invention particles of steel of each carbon analysis are crystallized and brou ht tcgether in the state admitting of welding and like particles are successively brought together in a regular manner whereby a mass of the two kinds of steel in regular alternation is accumulated while retaining a portion of their casting heat. As an instanceof the practical application of such a steel we ma refer to rope wire steel. rdinarily suc steel varies from .50 per cent carbon with a tensile strength of 180,000 lbs. er square inch to .8() per cent carbon wit a tensile strength of 265,000 lbs. per square inch after heat treatment in wire form. lf mixed to` gether in e ual quantities the resulting molten steel woul have'approximately .65 carbon with physical characteristics intermediate those of the original metals. By reducin particles of each steel separatel to a crystal.: plastic or welding condition and)1 placing them one upon the other in re lar alternatlon an accumulation of unifor y mixed metals results,vthe one of .50 carbon having its usual stren h, pliability and ease of bendin and the ot er of .80 carbon having its usuahigh strength, relative stiffness and low elongation. However, because of the fibrous nature of the mixture, the relatively small cross section ofeach metal particle, and the variablev metallic makeup, improved resistance to bending, vibration, twist and shock are obtained.

instead of mixing metals of the same base digerent metals may be advantageously combined. Copper wire used as long span electrical conductors lacks sucient stren h and is usually reinforced by steel in the crm of separate wire. By the practice of the present invention the steel is reduced iny a suitable slag to a plastic state and the copper likewise conditioned from 'either a comminuted or a molten state and in the relative metallic proportions of 15 pennant steel and 85 per cent lie Laoaaae copper they are assembled in alternation in the before-mentioned proportions, the copper completely enclosing the steel. The accumulated mass of copper and steel when Worked down into Wire possesses the conductivity oi the copper in the desired degree and the combined strength ot' the copper and steel suicient for requirements. It is obvious that varying proportions of metals may be so accumulated, the proportion just mentioned being by Way of example only.

These examples illustrate the procedure by which various metal combinations may be selected and accumulated. Small slag inclusions, inevitably entrapped with the metal or metals in any given accumulation of metal contribute a librous structure to the mass as the :further Working of the metal proceeds. Because of the relatively small aggregate of slag in any one position and the regularity of the positionin among the metal particles, a uniformity and degree of fineness of fibre is obtained which gives the metal marked superior qualities that enable it to resist vibration and shock. Fatigue of the metal is confined to individual fibres which when they break in two because of their individual character do not spread a crack across adjacent bers Whereas a crack on the surface of ordinary metal subjected to vibration travels continuously across the body until it is severed.

By a suitable arrangement of the mechanism employed in the operations of assembling metal particles after the manner of this invention, the casting or assembling operation is made continuous. To this end, a continuous slag supply, a continuous metal sup` ply, a continuous slag departure and a continuous metal departure are arranged While a continuous separation of slag and metal is etlected as the metal ,lparticles are sequentially Welded together. he arrangement maintains the growing or accumulating end of the metal mass at a Welding temperature so that arriving metal particles have no difficulty in edectin contact and substantial union under either gow or pressure with their sequential torerunning like particles.

The continuous casting arrangement is free trom the usual limitations imposed by the cooling rate of the metal by reason of the heat supplied by the slag. Heretofore, failure of continuous casting has been caused by lack of means to regulate the heat of the last cast particle to accommodate union with the next contacting particle. In the present invention the heat supplied by the slag as it dissipates from the metal may be replaced by heat from more slag Whereas the usual casting method is solely dependent upon utilizing the heat of the cast metal.

The first sectional portion of the continuously produced metal may be manipulated in a' Variety' ot Ways whereby its size -is in creased. Successive additions et metal may be made on both sides as the operation of casting continues from the molten state. Also the section of the metal may be immersed in molten slag at a Welding temperature and folded upon itself as it grows in length with each fold pressed upon the preceding one expressing the slag from therebetween and effecting a Welded union of adjacent surfaces. The folding operation may be continued until a body of metal accumulates of dimensions in accord With those of steel ingots in ordinary production. Because of the method of 'assembly'of the metal particles the cooling Yof the particles has taken place in the sequence of their placement resulting in the large mass of metal being free from the piping and other associated defects.

The successive layers of Welded and squeezed metal may be produced directly in a bath of slag. In this practice a layer o' metal particles is provided over the area of the bath and subjected to pressure effecting Welding and expression of slag from among the metal particles, successive layers being produced in like manner to build up a homogeneous mass with a minimum of slag inclusions.

In the practice of the invention, the cons tact of slag and metal results in the washing of the metal and the release of occluded gases so that the metal as solidified and linally assembled has a so-called homogeneous and fibrous characteristic condition when the slag used is in excess of that to be entrained in the metal to produce wrought iron. The Washing operation of the slag on the metal produces a cleansing eltect `which is highly advantageous in the manipulation of ferrous metals particularly. Due allowance for recaf moval of elements by the excess slag is taken by providing an excess of such elements in the molten body of metal to be cast so that the analysis of the final metal body will accord with specification requirements.

In the practice of this invention in the art of casting of single metals continuity of contact of the metal particles in their molten state and in the subsequent last-ic and Welded states is maintained. isintegration of the metal and intermingling of slag and metal particles are not desired for the reason that a higher percent rre ot slag would inevitably be entrap ed an thus alter the character of the pro uct desired. A continuous stream of metal or a continuous sheet of metal in the molten or plastic condition are desired with which or through which slag particles pass at a temperature Which produces or maintains a lastic or Welding condition of the metal. 'lihe purpose is to secure the quick crystal formation or solidifeation of the metal to avoid defects which ordinary expediente in casting do not obviate and to rene the metal structure by Working. The

quantity of slag involved must necessarily be greater than the quantity of metal in the operations involving washing ferrous metals in order to preserve the continuity of the opa erations where the slag is flowin and the movement of the metal after re uction to welding heat is relatively slow. The change in the rate of flow or linear movement of the metal and the change in direction of flow of the slag converts the energy of movement into force eective to force slag through the metal and to weld together newly associated metal particles under some conditions of operation.

The stream or sheet of molten metal provided in the casting operation under consideration acquires an increasing momentum as it departs trom its point of origin thereby becomin extremely attenuated. As the attenuation on itudinally increases the particles are crow ed together in a cross sectional direction thereby providing metal for maintaining continuity. When a sufficient body of metal is provided the attenuation may be eected in the cross sectional direction also. Crystallization of the metal and its accumulation may occur at a variety of points in the path provided and means for removal of the accumulations are provided and used in accordance with the quantity and condition of the metal.

1n castin a mixture of metals, the continuity of t e low percentage metal in the mixture while in the molten condition necessarily must be broken though it may a ain be established in the mixed body of meta Various means for effectin the gradual accumulation of metal particles from a molten state into a mass of metal free from 4.o physical defects are illustrated and described,

the means chosen for' any particular application being chosen for its special adaptability to the size of metal accumulation desired and to the characteristics of the metal mixture to 45 be accumulated.

Referring to the drawings,

Fi 1 shows a side and sectional view of a centrifugal Casting machine.

Fig. 2 shows a side view of the centrifugal so casting machine at right angles to the view of Fig. 1f

Fig. 3 shows a sectional view of a modification of the rotor illustrated in Fig. 1.

Fig. 4 shows a plan view of the rotor in 55 Fig. 3.

Fig. 5 shows the relative directions of movement oi centrifugally cast material and the wall upon which it is cast.

Fig. 6 shows another view of the moveao ment of centrifugally cast material as it is deposited on a receiver.

Fig. 7 shows a rotary deflector and anvil on which rests an accumulation of metal.

Fig. 8 shows a casting and coating operaes tion in progress between rolls.

Fig. 9 shows an accumulation of compressed cast metal.

Fig. 10 shows a side view of a roll type casting machine.

Fig. 11 shows a sectional view alon line A--A at right angles to the view of Fig. 11.

Fig. 12 shows a plan view of a pair of casting rolls.

Referring to Fig. 1 and Fig. 2, on a base plate 1 uprights 2, 3, 4, and 5 are mounted to which is attached a mid-cross plate 6 circular in shape and split across its diameter.

A bearing 7 in the center of the mid plate carries an inner linin 8 and an upper end ball race channel 9 w ich supports a spindle 10. The lower end of the spindle 10 carries a spider 11 on the outer rim of which a pulley 12 is mounted with a belt 13 thereon operatedand controlled from a source not shown. On the upper end of the spindle 10 a shoulder 14 carries a ball race channel 15 co-operatin with the race channel 9 on the mid-cross p ate to give stability to the spindle 10. The shoulder 14 also carries openings 16 into which fit extensions from a superposed bowl 17. The bowl has a depressed cup section 19 from which a Wall 20 extends upwardly. At the quarter points of the bowl 17 downward exits 21, 22, 23, 24 through the cup 19 are rovided. Rotary motion of the spindle 10 is transmitted to the bowl 17 through the extensions thereon littin into the openings 16 of the spindle. n the hollow of the spindle 10 frictionless bearings 26 and 27 support a slidable shaft 30 fitted with sliding keys 28 and 29 operative in the frictionless bearings 26 and 27. The upper end of the slidable shaft 30 extends through and opening 31 in the base of the bowl 17 and ts into the base opening 32 of a rotary anvil 33 and deflector 34. Below the spindle 10 and adjacent the pulley 12 thereon a pulley 35 carrying a belt 36 is mounted on the slidable shaft 30 and transmits motion thereto from a source not shown. The lower end of the slidable shaft 30 is supported by a shoulder 37 thereononafrictionless bearing 38 which receives an up and down motion through the rotation of a nut 39 contactin therewith. The lower end of the slidable s aft 30 extends through the nut 39 and into an associated threaded stationary base stud 40 resting on and attached to the base plate 1. A yoke 41 carrying a worm 42 encloses the nut 39 and positions the worinfor engagement with a worm-threaded shoulder 43 on the nut so that rotation of the worm causes rotation of the nut on the threaded stud which gives a longitudinal movement to the shaft 30 and to the anvil 33 and deector 34 thereon. Motion is transmitted to the screw 42 by a shaft 44 and universal joints 45 and 46v thereon from a stub shaft 47 in a bearing 48 attached to a frame upright 2. The stub shaft 47 lll esonero f oerries a pulley or hond Wheel 49 to which power is applied when up end down motion of the anvil and deector is desired.

Resting on the mid-cross plete 6 and between the trame uprights 2, 3, Il, and 5, is e circuler chamber with an upright outer will 50 enclosing the rotatable howl 17 and its associated anvil 33 and deilector 34. An inwardly projecting rim 5l extends around the top o' the chamber having an opening eucientlyT large to accommodate the removal et the howl i7 and associated anvil 33 and detlector ,34. The bottom 52 oi the circular chamber extends inwardl to s point edj scent the inner portion ot the owl at which point Y an inner Wall 53 entends upwardly to the vicinity of the bowl 17. A refractory lining 5o tits the full inside portion ot the circular cheminer, a narrow opening 56 on a level with the chamber bottom 52 and oi e. height approximeting the height of the inner Wall 53 ot the chamber leads to e spout 57 for draining the chamber into aA conveniently placed ladle 58.

@n one of the long trame uprights 2 a pair ot brackets 59 and 60 support a stationary shalt @i carrying collers t2, 63, end 64 which positifoiithree cross here 65, 66, 67 plivotally mounted on the upright shaft 61, t e op site end ot the cross hers being detscha ly enga ed by bolts #58, 69, 70, to the long frame uprig opposite the brackets 59 end 60. The cross hars d5, 66, sind 67, have Vcone shaped chambered mid sections 7l, 72, 7 3 respeetively into which lit cone shaped shells 7d, 75, 7o which ere concentric with the howl i7 heltrtT them which are ositioned one alcove the other with a space etofeen them such the three shells oceupgnositions on en imaginary continuous enclo oone. end 77 ot the lowermost cone is positioned in the vicinity ot the point 78 of the anvil 33 'with an intervening space 79 suiiciently large to sccommodate the assage of li nids in their downward course om the Shel 7 4, 75, 7 6. The upper edges of the shells 7d, 7 5, 76 are curved outwardly and downwardly formingn dri-ms 8l, 82, 83, respectively, and downwerdly and again upwsrdly forming chambers 84, 85, 86 resgectively with rims 87, 88, 89 respectively an `with speces 90 and lll hetweenthe shells. The shells ere su@- ciently refractory to withstand the heat of the materials contacting with them in the operations involved. The rims 87, 88, 89, are snoiently high to ceuse material poured into the clismloers (it, 85, 86 to dow over the dams til, 82, 83 .end down the inside of shells 74, 7 o, 7d to the common point 7 8 of the anvil helorr them. rillie cross bars 65, 66, 67 they he interchanged to position the shells 7s, 75, 76 to accommodate different pouring requirements.. The interspaces 90 and 91 between the shells rovide access for hond tools used in clearing eccumulations Within the shells durin operations. 'Extending across the tops oit" t e uprights 2 end i which support the cross bars 65, 6G and 67 is e cross bar 80, serving ss a tie har to the uprights to which it is attached end es a hesrmg 'for supporting hand bars or meohanicelly operated bars for clearing the inside of the shells 74, 7 5, 7 6.

Variations in the method oi? operation of the mechanism thus for described permit the production ol a variety of products. "Ehe preferred method oi o eration in the costing of steel requires that into each oi" the chambers 84:, 85, 86, of the conical shells 7l, 75, 76, hot molten slog should he poured et e. tempereture epproximeting the melting point of steel end in quantity suiiioient to overdow the shell dams 8l, S2, 83 and the inner sur faces ot the shells 74, 75, 76, from which it ows onto the rotating enril 33 and the dedect/or 34 which pass it on to the rotating wall 20 of the bowl 17 from which it lows out ot the openings 21, 22, 23, 2li, in the cup of the bowl 17 to the chamber lining around and under the howl and ont ot" the chamber opening 56 and the spout 57 to the slag hiiclret 58. Alter posseggo oil the has heated the various arts with which it contacts to temperatures iigh enough for opstating purposes, the sieg lion' is stopped.

Molten steel is then poured. into the midpositioned chamber 85 While molten slag or Welding cinder at a temperature around the Welding point tor steel is cured into the upper positioned chamber d ,the pouring; oit l the slag and steel at rates of' two to three volumes of slog to one relents oi? steel causing an overdow ot' the dfn-ms ond irtl the slag impacting upon the as the overows its chamber darn 82. The impact ot' -the slag on the steel accelerates the lloro of the letter over the lower positioned shells 75 and 76 While an interchange of heat between the slag and steel occurs. Flhe greater weight of the steel keeps it in contect with the refractory shell with the sieg on top rotecting,r from Y atmospheric oxidetion. dolten clog poured into the lower positioned chamber 86 overdowing the shell dam 83 contacte "with the steel and is entreined therein ,end forced therethrough providing s, Washing action on the steel. impact oi? the slag and steel on the trimming1 enril gives them a spreading section following; the

tenuation eccornpanring; the idool down the shells. The slag' on the inside ot the de soending tube ot and steel forced through the steel the moss is delleoted from its vertical petit. Rotation oi the de Hector 3l is in one direction oi the howl impelled against the howl Well 2G. impact of the moss on the rototing howl Wall Q0 eatest in the diwl, forcing the causes a s reading action,

rection o rotation of the slag from perforations in the metal and wading the metal with a minimum of slag 5 inclusions. An up and down motion of the deector eects a folding of the metal upon itself as it accumulates on the bowl wall 20. The u and down motion is produced by manna or other operation of the elements identified by numerals to 49 inclusive in the oreceding paragraphs 'l e excess slag passes from the bowl by a path de endent u n the rate of bowl rotation. l the rate 1s relatively slow, the exit is by downward openin 21, 22, 23, 24, from the bowl cup and if ne atively fast the exit is by the upward path over the bowl wall 20, to the chamber lining and in either case out of the chamber openin 56 and over the spout 57 there positioned into the slag bucket 38.

rlhe change from the molten to the plastic state by the steel becomes operative wlth the first Contact of slag and steel in s. degree dependent upon their diderences in temperature and continuing until the steel is welded into position in the accumulation on the bowl wall. The volume of steel ma be lessened and the volume of the sla inc usions forms within the mid position@ shell and moving downwardly under the impulse of the movin slag and compressing in diameter into e lower positioned shell where it is rtber'compressed and welded. lf the taper of the shells does not accommodate the movement of the rin force thereon by hand or power tools may is exerted downwardly through the center forcing the ring past the bottom 77 of the lower shell and over the anvil 33. lt is obvious that as the metnllic ring descends its entrained slag content decreases due to the expressing of slag toward the inside of the ring in consequence of the 'change from the large to the smaller diameter. Successive rings deposited on the anvil 33 and continually washed by the descending sla at welding temperature weld together te erm a mass of slag and steel somewhat approaching puddled iron in its slag con- 5@ tent.

Removal of the.metal cast in the bowl is e'ected by removing the bolt 70 fastening the lower cross bar 67 to the frame upright e and swinging the bar about the pivot shaft 61 at its other end thereb removing the lower shell 76 from over t e bowl 17, and then lifting the ring of metal from the tapered wall 20 of the bowl through the upper opening of the bowl chamber and sidewise through the space cleared by the lower shell travel.

Removal of the metal impaled on the anvil 33 and defiector 34 is effected in a similar vertical and sidewise lifting movement. C@ Removal of metal trom e shell is readily Leccese edected upwardly while the superposed shell is swung to one side.

After the metal is removed, it is subjected to rolling or other metal working operations while still possessing some of its heat 'of casting.

By making the intervening space 79 between the lower shell 77 and the point 78 of the anvil 33 suiciently large, successive rings of met-al may be removed therethrough from the deflector 34 and the anvil 33, thus making the operation of the rocess practically continuous. Also by Imaging it sufcientl small, a ring of metal may contact with both the superposed shell and the under poised anvil practically closing the passage from the shell until ressure on the ring forces it downward on tlie anvil. With the shell Sulliciently well supported, the up and down motion of the anvil ma be utilized to effect the working and wit drawal of the metal from the shell.

lt is apparent that various reacting materials may be introduced into the metal or metal and slag through the spaces 90 and 91 between the shells or throu h the upper end openings of the shells so t at reactions more or less violent may safely take lace within the shell enclosure as the metal ows downward within the shell from the chamas ber around its upper section. Also the character of the slag or cooling medium ma be other than that of the siliceous pud ing cinder. The apparatus lends itsel readily to practices such as that of Patent 511,648 30eby Parkinson using a slag not of puddling characteristics. Obviously the mixing shells 74:, 75 and 76 may be used toentram slag particles in metal without'rotating the anvil 33 and the bowl 17.

A. variety of metals may be poured individually each into its individual shell chamber to pursue its course downward within the Shells with the other metals to the anvil and deilector from whence they ma be de- Me l tion on the revolving wall 20 may eect a l welding of the particles in their ositions, an action which is contrary to te action where ordinary centrifugal casting is used. However, special apparatus may advantaeously be employed for simultaneousl cast- 120 ing diderent materials in a single bo y and such apparatus is now to be considered.-

In Fig. 3 and Fig. t sectional and plan views respectively of modificationsof appar. ratus are shown.

Cooling tanks 93, 94, 95 are d at quarter points between the frame uprights 2, 3, a, 5 over hooks 97, 98, 99 respectively and retained in position thereon on the outer wall 50 of the large operating chamber. 1l

ses,"

. given p Pipes 101, 102, 103 on the respective tanks furnish passages for the suitable cooling medium. Inside the large chamber and at the quarter points opposite the frame uprights 2, 3, 4, 5, are positioned the dividers 104, 105, 106, 107, which are operative to divide the metal deposited on the inside of wall 50 into lengths facilitating their removal. The bowl 17 is provided with an inner lower ring 108 held in position by frictional engagement, and inner upper ring 109 held in position by clips 110 extending through passages 111 in the rim 20 of the bowl 17. Rotation ofthebowl causes the clips to retain their position by centrifugal action. The position of the usual anvil 83 and deector 34 is occupiedby a special distributor 112 adapted to rotary movement through engagement with the slidable shaft 30. Concentric chambers 113 and 114 have separate exit passages 115 and 116 respectively eX- tending radially and opposite from each other. The exit passages are of a converging channel shape so that a continuous stream of metal may be supplied to the oriiices 117 and 118 as the rate of travel in the paages increases during rotation. An accessory defiector plate 119 on the upper side of the rotor serves during rotation to direct any material dropped thereon into the surrounding bowl 17 or into the large chamber beyond the bowl in the event that the bowl is not in its operating position. The concentric position of the chambers 113 and 114 with respect to the superposed pouringr shells is contemplated in order that each chamber may be supplied with material in accordance with a chosen operating plan.

In operation, the special modification just described may advantageously be used for the production of the special ro e wire steel previously referred to; steel o the higher carbon grade and slag may be poured in the center chamber 113 and steel of the lower carbon grade and slag into the outer chamber 114 at rates and temperatures so that as each steel emerges from its nozzle a plastic condition or near lastic condition is present as the centri ugal action carries the metal to bowl lining 122 for spreading there-- in. When the metal arrives in a stream, any article of metal must make half a revolution relative to the stream source when the two streams are operative before another particle of different metal is spread thereon p giving a time interval and means for cooling from plastic to welded state, and the impact of the next particle provides the necessary force to complete the welding operation of the preceding superposed articles. Thus in eect a thin strip of meta and cinder is deposited upon which a succeeding layer is placed, the two layers cooling to welding temperatur-esami succeeding layers by impact thereon completing the welding operation. The continuity of the operation builds up a body of composite meta-.l and cinder of a fibrous structure new to the art.

The structure of the casting has a smaller grain structure than is found in bodies of metal of the same size cast by previous methods for the reason that the time interval between pouring and solidification of any given particle is less in the practice of the present invention and the solidication takes place. in progression from one side of the casting to the other instead of from both sides inwardly. The body is cast in increments which solidify in the order of placement Vso that the two metals are forced to retain their relative positions as placed.

In the continued operation of assembling the two metals, the slag is removed from the space between the bowl rings by displace ment by the steel, iowinr over the upper ring when rotation thereofj provides the necessary force and otherwise flowing over the lower ring only and downwardly through the openings in the depressed cup section of the bowl.

Removal of the metal from the bowl is effected by removing the clips from the up per edge of the bowl also the upper ring after which the ring of metal 1s readily lifted upward. The metal thus removed is then subjected to the usual metal working operations. If the ring is desired in sections, suitable dividers may be placed at intervals between the rings in the bowl.

The relative sizes of the nozzles 117 and 118 regulates the relative rates of How of the metals and their accompanying cooling niedium and the accompanying rates of pouring where continuous iiow of metal is desired. The cooling medium for each metal must be of a composition that does not cause deleterious efi'ects when entrained in the composite metal accumulation and may be powdered as well as Huid.

In Fig. 5 is shown a partial plan view of the bowl 17 showin the rim and cup only. Radial arrows 120 s ow the direction of ap# proach by metal and slag particles to the rim 20, while circumferential arrows 121 show the direction of rotation of the rim 20 'and cup 19. It is obvious that as the particle of metal or slag in its radial movement contacts with the circumferential rotating rim 2O a s reading action occurs in the direction of the circumferential movement of the rim causing a. much reater attenuation of the arriving article t an would occur under impact alone. he an lar movement of the wall 2O relative .to thefilection of approach of the metal and slag as they impact on the wall with a plastic condition of the metal is particularly eiective in its operation.

In F' 6 is shown a vertical wall section of end clone the wall 2O of the bowl 17 a thin inner reiiiactory lining 122 is positioned to give protection to the vessel When extremely high temperature material is to be encountered. Due to the up and down movement of the deiiector 34 or of the special distributor 112. metal is deposited in a series of folds 123 124i, which tends to result in a laminated structure of the resulting bod of metal. it is obvious thet the number of olds is depend ent upon the rate of the up end dovvn movement of the distributor and upon the rate of :tlovv of metal. The successive folds of metal Weld together as they form so that a solid mess of metal results when the temperature during cesting permits and such procedure is preferable.

1n Fig. 7 is shown the envil 33 and deector 34; with en accumulation of articles of metal 125 thereon cast end wel ed tovether. A smell dow ot metel end slag initiay permite the ormetion oit' e ring nuc eus to' which succemive perticles of metal Weld es they arrive end @om which excess sla is projected by the rotation of the mass and y ravity. The ring stretches over the anvil un er the impact or" errivin metel end sie until its strenth increased by cooling on t e deiieotor is a, le

to resist the further impacting action sitter' which accumulation takes place in the u vvsrdly direction. `{Upon removal from t e envil 33 the mass of metal may be Worked into coerciel bars or shams while retaining some oi the heet of casting. Speed ci rotation of the anvil during the forming o erstion is governed to accord with the con i tion of the grot-vin accumulation, being slow the start, acce ereted later, and varied :trom time to time es required to retain the metal in the ring. y

ln Fig. 8 is shown a sectional view oit e pair orD driven rolls 126 and 127 with Water cooled .besis for a successful continuous cestino operetion in the handling of steel.

ther metsls may be handled in a similar manner with the slag and operating temperatures being chosen end maintained to eccord tv'ith the casting characteristics of the particular metal lbeing cest. A complete operating mechanisni employin the roll e ui ment just described wvill be escribed an i nsti-ated later. Fig. 9 is shown a simplified apparatus means. '1t is obvious t tenesse dition. lnto the ladle 140 slag 142 of Weld ing cinder characteristics is introduced to serve as a heating medium :tor layers of cast metal 143 therein super-posed on one another. Poised ebove the ladle 140 is shown s. plunger or pressure means 144 operated by ineens not shown and operative to press the successive layers of cast metal 143 together end to complete their Welding together While forcing the slag 142 from between the motel particles. rEhe-successive layers of cast metal may be cest and pressed exteriorly of the ladle and thenbe introduced into the lsdle or they may be cast in the ladle individually7 each bein pressed out forcing the slag from between t e layers and metal particles layer by layer to complete the welding into a solid mass. Successive layers of motel msly be Welded together sucient to form a mass the equivalent of the usual comercial steel in-V got. The mass because of its manner of essembly, particle by particle in a Welding operation insteed of solidilication from e arge molten mass, is-free from the waste and de- Vects ordinarily encountered such es piping, .blowholes and segregation. rlhe slag content is controlled by the thickness of layers cast and the lpressures applied in their Welding, the smal masses of metal being operated on et any one time facilitetin the control operations. Drainage of slag rom the ladle is eiectedes required from time to time through opening 141 in the bottom from which e clay lp ug may be removed by et the slag tempereture must be belder the nieltino point. of the `metal in. order that the meterla mey be in s vveldable state, otherwise e. molten metal condition would be resent and nullify ell the provisions in han The volume of slag, rate of castin and casting metal tem eratures must be given due consideration in t e operations involved. These factors may even 4be controlled to the extent of incorporating practicallyell of the slag into the metal cest so that no appreciable surplus remains exte- -riorly of themetal after the operations involved ere com leted. f

. ln-FigflOv is s own a side view and in Fig; 11e. sectional view of amachine for continuouslyeasting metal into sheets or strips for assembly efter the manner just described, in connection with Fig. 9, into Ian ingot, or for direct further extension-by the usual rollin or drawing operations. 0n e bese plete 1t ere mounted two upright vend frame plates 146 end 147 which are joined across the to by tvvo tie plates 143 end lM9. Entendjing through suitable bearings 150 and 151 in the end pistes is a drive shaft 152 carryin on one end s pQWer-connection not shown an on the other end a, pinion 153 positioned to one side e, hand ber or other end intermediate of an upper gear 154 and a 1130 t e rolls the same rate of rotation.

lower gear 155 respectivel which it drives. The u per gear is attache to one end of one roll 15 of a pair of parallel cooperating rolls 156 and 157 extending parallel .to the drive shaft and with bearings 158, 159, 160, 161 in the end frame plates. On the ends of the rolls opposite to the upper gear 154 a pair of pinions 162 and 163 give the rolls the same rate of rotation. The lower gear 155 is attached to the end of one roll of a pair of cooperatin rolls parallel to and directly below the set o rolls just mentioned, and journaled in bearings 164, 165, 166, 167 in the end plates. 0n the ends of the rolls opposite to the lower ear 155 a pair of pinions 168 and 169 give The bearings of the upper inion driven roll and of the lower pinion riven roll are adjustable horizontall by means ofremovable plates 170, 171, 1'72, 1 3 so that the space between the two rolls of either air ma be suitably arranged. Each roll as beve ed shoulder portions 174 next 'to which on one side is the end bearing section 175 and on the other side a cylindrical section 176. Between the cylindrical sections a grooved section 177 is positioned. Adjacent beveled shoulders of a pair of rolls form a V notch, adjacent cylindrical sections contact with each otherand ad'acent grooved sections form the outline o a assage between the rolls. Each roll has a liollow central chamber 178 with end exits 179 and pipe connections 180 for s-upplying a cooling medium to the central chamber. Above the upper pair of rolls and supported on the end plates, a pair of concentric pouring shells 181 and 182 are arranged. A similar pair of pouring shells 183 and 184 are arranged and supported intermediate of the upper and lower pairs of rolls. The shells adjacent the rolls have dependin end portions 185, 186, 187, 188 extending ownwardly to the vicinity of the rolls to partiall restrain any solid or plastic material rom movement toward the ends of the rolls while permitting the ow of liquids endwise of the rolls when poured thereon. Each shell 181, 182, 183, 184 respectively has its depending tapering chamber portion 189, 190, 191, 192 respectively around the top of which extends an inner lip portion 193, 194, 195, 196 respectively and an outer trough portion 197, 198, 199, 200 respectively, and an outer lip portion 201, 202, 203, 204 respectively somewhat higher than the inner lip portion. Also at one end of each shell 182, 183, 184, 185 a feed trough 205, 206, 207, 208 respectively and a guide wall 209, 210, 211, 212 respectively with a. hole therethrough `213, 214, 215, 216 respectively provides a guide for the flow of liquids into the trough portions 205, 206, 207, 208 res ectively from which it Hows down the inc ined depending shell portion onto the rolls. Below the lower pair of rolls and extendin angularly downward and to the exit side l the machine between the end plates 146 and 147 and attached thereto is positioned an apron 217 on which liquid material drops from the rolls with the solid material passing from between the rolls. Due to the roll action, solid material from between the rolls is pressed against the apron 217 and over a trough 218 to suitable receiving means in accordance with the further working which it is to receive. The liquid Hows down the apron 217 to a trough 218 extending downwardly and inclined to one end of the machine draining into a ladle 219 for removal to a furnace for further use,

The concentric pouring shells are open at the tops and afford a direct passage to the rolls so that access to the rolls is always available for employment/of hand tools upon the material upon the rolls, for pouring hot metal directly to the rolls from a ladle, or for the introduction of strip material to be coated between the rolls.

In the operation of the embodiment shown in Fig. 10 and Fig. 11, for casting steel, a thin temporary cross strip is placed in a folded position between each pair of rolls so as to form a dam therebetween and to feed between the rolls when they rotate. The osition and action of the strip is illustrated y Fig. 8 where the ends 132 and 133 may be regarded as those of the folded strip. After warming'the operating parts of the machine by pouring molten slag at a welding temperature of steel into the various shells, the operation of the castin is started by pouring welding cinder at we ding heat over the upper shells of each pair of rolls while molten steel is poured from the shell 182 above and adjacent to the upper pair of rolls resulting in the formation of a pasty mass of weldable steel covered with slag on the so-called dam. The rolls 156 and 157 are then rotated at a rate in harmony with the rate of formation of the pasty mass of steel so that the dam passes between the rolls as the first end of a strip of welded and squeezed metal, rotation of the rolls serving to reduce the thickness of the metal mass, squeezing out the excess welding cinder and welding the metal particles into a coherent body. While the metal passes between the rolls 156 and 157 the molten welding cinder passes longitudinally of the rolls 156 and 157 and then downward inside the lower shell 184 and onto the second pair of rolls 174 and 175 from whence it flows onto the apron and thc trough 218 and then into the ladle 219. As the lower end of the newly formed strip of metal passes between the lower pair of rolls while additions are being made to the upper end of the strip, a pasty mass of metal is formed on both sides of the product of the upper rolls while the lower pair of rolls 174 and 175 reduces the size of the pasty metal mass, squeezing out the excess welding cinder and welding the particles into a coherent illunrated in lll@ ' he liquid owing fos ' lower pair of rolls 17 4 and 175 is suciently greater than the space between the up er pair of rolls 156 and 157 to accommodate t e addition to the strip from the upper rolls of appreciable quantities of metal by the casting and welding operation inst described. Y

As the strip continues to grow, its forward end is primed yover the a ron 217 and the trough 218 ot the machine or further manipulation in accord with the operating 1an chosen. @ne plan of o ration contemp ates folding and welding t e folds together in a sla-g or vveldin cinder heating medium, as ig. 9 and described in connection therewith. Another plan of operation contemplates the. prompt reduction byV working while still retaining some of its heat of casting.

The shape of the strip produced by thisembodiment is controlled b the shape of the rolls. lnsteadof a sin le at strip resulting from the operation, a p uralit of near cylindrical strips may be produce by employing suitably ved rolls.' lteferrin to Fig. l2 in a p an view is shown S pair o caved rolls 220 and 221 in contact with eac other along cylindrical portions 222 and 223 'om the cylindrical portions of which extend bev sled sections 224 and 225 to cylindrical hearing sections 226 and 227 respectively. ABetween the contacting c lindrical portions 222 and 223 ot the pair o rolls are grooved sec-f tions 228 and 229 with edges 230 and 231 which by their adjacent positioning and cooperative action squeeze plastic material when placed thereon by their rotary movement into cylindrical sections which pass downwardly through the circular passe es formed hy the adjacent grooves. T e jacent cylindrical sections 222 and 223 form a trough over which liquid matter accompanying and expressed from the plastic material Hows to the V or notch section formed by adacent bevel sections 224 and 225 of the rolls. away serves to convey heat from the plastic material and to cool the rolls which may be internally cooledby a se erste medium as previously descri I The advantages o my invention result from reducing a cast metal from. a uiduto s, plastic state during the placement of the metal in its cast position. liquid character, its ability to migrate m position to cooling is estro ed. The phenomena that ordinarily mani est themse ves during the change from the liqiid to the solid metallic state are nullitied. t is characteristic of the invention that from a liquid metal a plomic nucleus is formed to which perticlesof like metal are united progressively or to which y destroyin its' 'tion in the casting during its.k

neo-onse the metals as would be present in any other portion, in the case of the copper and steel previously referred to, the copper 85 per cent and steel per. cent. The copper acts as a matrix enclosing the steel and the uniformit of the combination is obtained by the positioning of 85 units of plastic cop er and 15 units of steel regularly during t e casting operation, migration of the dierent units being forestalled by their prereduction from molten to plastic condition.

In settin forth the steps for securing the plastic conlitions of the cast metals, continued reference has been made to the use of slags of suitable characteristics. These are chosen because of their indiierence to the metals. Silica combines readily with protoxide of iro'n and forms easily fusible silicates with which two pieces o iron at a welding heat may be coated and yet weld soundly together-under pressure the interposed 1i uid silicate "biting expelled in a greater or ess degree leaving `clean bright. metallic surfaces'of the metal to come iii contact under pressure,l The tribasic silicate of protoxide of iron tem ratures and would indeed protect t sur ace from oxidation and keep it bright. lA silicate of this kind which is termed a weldling cinder is desirable for the reduction of metal has a suitable weldin cinder for use in connection with the practice of this invention. However, the practice of this invention is not limited to the employment of slugs, either molten or powders as means for obtaining the plastic and subsequently welded states. Metals, either molten or powdered, of relativel lower melting point than the metal regarde as the castin metal may he employed. Copperma e used for casting steel, in `which case t e copper is within the welding range of temperature of the steel. As it becomes welded in the copper, an alloy of steel and co per is formed which it'is desirable to kee elovv 3% of copper and above 97% steel,- as 'gli ercente s otcopper with the steel prwent p ysieal c aracteristi not desirable. Alsoin the steel matrix pure copperie held inY rcentages depending upon the .masses an pressures fused during' the "weldingoperatona- This is in contrast to the previously mentioned combination of copper 85 mrfcent and steel 15 per cent where the ycopper' serves as a matrix holding the steel in definite placement.

While suitable slags are indierent to the metals being cast, the metalloids in the mixtures with the metals are sometimes attacked to the detriment of the nal product unless 'lllI is has no action on metallic iron at hih ico ferrous mixtures to the plastic state. Each ian iso

\ cess slag particles.

Lacasse due precautions are employed. Such precautions involve the provision of an excess of the rnetalloids beyond the requirements of the final product in the solid condition particularly when washing by slag is practiced. When slag approximately in an amount to be incorporated in the cast metal and in either Wdered or molten condition or of a reguated specific gravity is chosen, such precautions referred to are not so essential. Whether these metalloids are in the metal prior to the casting process or Whether they are added during the process of casting is immaterial. The use of a slag to cover a metal, which is to reduce another metal to a lastic state is contemplated. Thus, copper into which steel may be cast ma be covered with slag which may serve the ual purpose of protecting the copper andreducing the alloy'ing action between the copper and steel.

Many changes may be made in the apparatus employed, as Well as in the steps of my process without departing from my invention. Within the scope of my claims, parts of my complete rocess forming sub-processes may be use without departing from my invention. The materials used, the pressure apparatus and the receiving apparatus ma be Widely varied.

claim:

l. In the process of casting metal, the steps consisting of entraining welding slag particles in a body of molten metal thereby reducing the metal to weldin temperature, welding the metal into a soli' body and exressin excess slag particles While continuing sai entraining o eration.

2. In'the process o castin steel, the steps consisting of entraining We ding sla particles in a body of molten steel there y reducing the said steel to Welding temperature, expressing excess slag particles and welding the metal into a solid body While continuing said entraining operation.

3. The method of casting metal comprising the steps of entraining slag particles in a body of molten metal thereby reducing the metal to Welding temperature, welding the body of metal upon itself and expressing ex- 4. The method of casting metal, consisting in changing the molten metal into a coherent mass by contact with cooling means comprising metaler slag or both so obtaining the welding temperature range of the metal being'cast, expressing entrained portions of the liquid cooling means from said coherent mass and welding the metal where perforated by said expressed entrained portions.

5. The method of' casting metal, consisting in changing the molten metal into a coherent mass by contact with liquid cooling means comprising either metal or slag Within the Welding temperature range of the metal being cast, expressing entrained portions of the liquid coolin means from Said coherent mass and ad ing progressively metal to said coherent mass.

6. In the process of casting metal, the steps consisting of entraining material particles in a body of molten metal thereby reducing the metal to Welding temperature, expressing excess material particles while continuing said entraining o eration, and welding the metal into a solid ody.

7 In the process of casting steel, the Steps consisting o changing the molten metal into a weldable condition while retaining some of the heat of casting, welding metal particles together under the protection of a weldin slag, expressing entrained portion of sai slag, and progressively casting additional particles on the Welded mass.

8. The method of casting metal, consisting in adding additional metalloids to the molten metal, changing the molten metal into a coherent mass by contact with cooling means comprising metal or slag or both so that a mean temperature Within the welding range of the cast metal results and expressing entrained portions of the cooling means om said coherent mass.

9. In the process of casting a ferrous metalv to the molten steel to be cast, then forcing a slag of puddling characteristics therethrough while the metal is being cast, Whereby the metal is cooled.

11. The method of casting a. plurality of metals into a sin le mass comprising the steps of reducing each metal from a molten to a welding condition, welding said metals together in small particles, and re atedly add-' ing small particles in regular a ternation of 1 metals by welding while retaining heat from y l the ori nal castin 12. lg1 g the step consistin of adding a protective metalloid to the loy steel to be cast, then forcing a slag of puddling characteristics therethrough while the metal is being cast, whereby the metal is cooled.

13. In the process of casting steel into an alloy the'step consisting of addin a protective metalloid to the molten stee simultaneously castin the molten steel into contact with an alloying metal and forcing a slag of puddling characteristics therethrough.

14. In the process of castin metal, the step consisting of forcing a slag o puddling characteristics therethrou h while the metal is being cast and regulating the temperature of n the process of casting an. alloy steel,

Y sesame,

the slag within the welding range of the metal.

15. ln the process of casting ferrous metal,

theste consisting of forcing a slag of pud- 5 (lling c aracteristics through the metal While the metal is being cast, regulatin the temperature of the slag Within the wel ing range of the metal and Welding the meta-l.

16. As an article of manufacture, a, comm, posite metal body comprising a plurality of metal particles havin an individual analysis, between said partic es a pluralit of metal particleshaving another individua anal sis, said particles being Welded along their ces 5 of contact from a plastic state While preservin Within their lines of contact each its indivi ual analysis.

17. As an article of manufacture, a composite metal body comprising a plurality of g3g steel particles having the same analysis, between said particles a lurality of metal particles of another ana ysis, and a weld between adjacent particles so positioned eRective to hold them as a body.

as 18. As an article of manufacture, a composite metal body comprising a plurality of steel particles having the same analysis, between said articles a plurality of articles of steel having another analysis, an a weld 3a between adjacent particles so positioned effective to hold them as a body.

19, A casting machine comprising a molten metal supply means, a molten slag supply means, means for contacting said slag on said 35 metal whereby the temperature of said metal is reduced to a Weldin range,and weldin means eective to wel together said meta in the Welding temperature range.

lin testimony wof aix msilgnature.

Vi: t E.' 

